BROOKHAVEN NATIONAL LABORATORY
POLLUTION PREVENTION, WASTE REDUCTION AND RECYCLING PROJECTS (CY 2004) TRACKING SYSTEM
WASTE DESCRIPTION TYPE OF PROJECT POUNDS REDUCED, REUSED, RECYCLED OR CONSERVED IN 2004 WASTE TYPE POTENTIAL COSTS FOR TREATMENT & DISPOSAL COST OF RECYCLE, PREVENTION ESTIMATED COST SAVINGS PROJECT DESCRIPTION DETAILS *
Automotive Waste Substitution 510 Hazardous Waste $1,020 $1,000 $1,000 Aqueous Solvent Brake Cleaner Recycling System
Mercury Utility Devices Substitution 60 Hazardous Waste $1,750 $2,500 $1,750 Approximately 60 pounds of mercury containing devices were removed from Buildings 463 and 490.  Savings are based on the cost of one mercury spill and clean-up event.
PCB Oils Retrofill 1,200 Hazardous Waste $2,850 $3,450 $2,850 Approximately 150 gallons of PCB laden oil was removed from the ATF Klystron.  Savings are based on the cost of one PCB spill and clean-up event.
Organic Solvents Substitution 678 Hazardous Waste $1,355 $36,500 $26,000 Life Sciences purchased a Microwave Peptide Synthesizer, which significantly reduces the amount of hazardous wastes generated and saves approximately 1000 man hours/year.
Organic Solvents Purification 480 Hazardous Waste $960 $24,000 $10,915 BES solvent purification system - primary cost saving is in not purchasing new solvent.
Cooling Water Reuse 80,000 Deionized water $0 $6,000 $10,000 Closed-Cycle water recycling system for building 480 melt spinner saves a minimium of 10,000 of ultra-pure water and extends the life expentency on a $100,000 piece of equipment.
PCB Oils Removal 3,110 Hazardous Waste $6,220 $10,000 $2,850 Approximately 300 gallons of pure PCB oil was drained from the transformer and rectifer in 901 (old PET Facility).  In addition, 30 PCB capacators and 11 PCB transformers were removed.  Savings are based on the cost of one PCB spill and clean-up event.
Mercury Utility Devices Substitution 40 Hazardous Waste $2,300 $2,500 $1,750 OMC replaced their mercury containing equipment with non-mercury containing equipment.  Savings are based on the cost of one PCB spill and clean-up event.
Radioactive Waste Source Reduction 1,500 Radioactive Waste $6,000 $2,500 $6,000 Waste Yard Sorting Table surveying to sort clean waste from radioactive waste
Radioactive Emissions Emission Reduction 0 Radioactive Emissions     $0 Installation of a shroud to fit over the 16-inch diameter shaft residing within the Hot Cell of the BLIP, thereby isolating the cooling water from the rapidly moving air of the exhaust system and allowing radiological decay within the water system. Slowing the diffusion into the hot cell air will effectively reduce gaseous emissions into the exhaust stack because these radionuclides have very short half lives. 
Radioactive Waste generated through wet chemistry Waste Minimization 30 Mixed waste / Liquid Radioactive Waste $17,600 $0 $22,500 Elimination of mixed waste with a Kinetic Phosphorescence Analyzer (KPA) system for uranium analysis. Eliminates mixed waste generation, reduces by 90% the volume of liquid waste, reduces by 90% the amount of radioactive material handled in the laboratory, minimizes exposure to U by laboratory personnel, and decreases total labor time by 75%.
Radioactive Waste from labeled chemicals Waste Minimization/ Volume Reduction 0 Solid Radioactive Waste $2,168 $0 $2,168 Vial Crusher for glass vials, pipettes, and other glassware
Radioactive and Mixed Wastes from radio-labeled chemicals Waste Minimization 112 Mixed Waste $27,690 $0 $27,690 microplate scintillation counter for reduction in mixed waste generation
Pump Oil Substitution 51 Hazardous Waste / Industrial Waste $3,520 $0 $3,520 Replaced oil-displacement pumps with dry pumps for both laboratory and aircraft missions.  
Photographic Waste Substitution 3,840 Hazardous Waste / Industrial Waste $7,600 $0 $16,489 This new photographic processor reduces the amount of chemicals used and waste generated by up to 80%.
Electrophoretic Mini-Gels Microscale Chemical Use 2,200 Hazardous Waste - Lab Pack $10,400 $0 $10,400 Minimization of Silver Waste from Silver-Staining Electrophoretic Mini-Gels.  Savings reflect avoided waste disposal costs and lower material purchase costs ($6000)
Hydraulic Oil Product Substitution 1,000 Industrial Waste $17,000 $0 $17,000 Retrofit of Garbage Truck Hydraulics With Steel-braded Hydraulic Lines and a Vegetable Based Hydraulic Oil.  This project will reduce the number of reportable spills along with the subsequent clean up costs ($15,000).
Hydraulic Oil Product Substitution 3,000 Industrial Waste $26,000 $0 $26,000 Retrofit of Hydraulic Lift Bays in Motor Pool Shop to Vegetable Based Hydraulic Oil.  This project minimized the potential for petroleum based hydraulic oil leaks/spills and subsequent clean up costs ($20,000)
Sewage Sludge Volume Reduction 234,000 Radioactive Waste $910,000 $0 $910,000 60,000 gallons of radioactive STP liquid waste could have been disposed of through a contractor at a cost of $910,000.  Instead, the waste was dried using rolloffs, absorbent and lime and sent off for disposal via rail cars.  In addition, a second drying bed was built to dry sludge (96% volume reduction) from the anaerobic sludge digester..
CO2 Snow Cleaning Source Reduction 0 Hazardous Waste / Industrial Waste $5,000 $0 $0 Equipment purchased to evaluate CO2 Snow Cleaning for NSLS, Instrumentation and CAD applications.  This project has the potential to reduce solvent usage (hazwaste), and aqueous cleaning wastes (industrial waste).  Limited success due to moisture condensation.
Film and other radioisotopic imaging  Substitution 300 Hazardous Waste / Industrial Waste $22,000 $0 $22,000 Replacement of Film-based Autoradiography and other radioisotopic imaging  with a Phosphor Imager reduced hazardous waste generation by 200 pounds and industrial waste generation by 100 pounds.  There are additional projected savings in annual supply costs ($3,000) and labor reduction ($15,000)
Digital Imaging System Substitution 282 Hazardous Waste / Radioactive Waste / Industrial Waste $25,000 $0 $25,000 Reduction of hazardous (134 lbs), radioactive (80 lbs) and industrial waste (68 lbs) with a digital imaging system.  There are additional projected savings in annual supply costs ($3,000) and labor reduction ($20,000)
Fluorescence-Based Assay Substitution 200 Mixed Waste $30,550 $0 $30,550 Development of a fluorescence-based assay for the DNA-dependent protein kinase (DNA-PKcs) to replace current 32P assay
Lead Acid Batteries Recycled 9,800 Hazardous Waste $19,600 $0 $19,600 Estimate 40 lbs./battery and avoided disposal costs as hazardous waste.
Ion Exchange wastewater Source Reduction 1250 Hazardous and Sanitary Wastewater $2,500 $100 $2,400 Prefilters were added to the deionization system to polish make up water entering the ion exchange system. This extended the useful life of the ion exchange resins, requiring less frequent regeneration. The regeneration process generates hazardous and sanitary wastewaters.
Tritium Exit Signs Source Reduction 568 Mixed Waste $119,280 $10,650 $108,630 Removed 142 tritium exit signs from service and returned to the manufacturer . Replaced with energy efficient light emitting diode (LED) signs. Project reduced risk of tritium gas release and avoided disposal as mixed waste (70 ft3).
Cooling Water Reuse 34,850 Radioactive Waste $80,155 $0 $80,155 Approximately 18,000 gallons (153,000 lbs) of cooling water was reused in the main magnet cooling water system, avoiding disposal as radioactive waste water. Mel's number
Short Half-life waste Decay in Storage 627 Radioactive Waste $1,499 $0 $1,499 Short half-life isotopes, particularly phosphorus-32 and phosphorus-33, are frequently used in life sciences experiments. Wastes generated from these operations (10 ft3)were managed in accordance with BNL decay-in-storage requirements, rendering the wastes eligible for volumetric release.  Steve's Number
Oily Waste Water Source Reduction 6,240 Industrial Waste $20,280 $0 $20,280 This project, funded by the pollution prevention council during calendar year 2001, installed automatic oil-water separators on compressor blowdown stations. These units capture the oily discharge and save significant labor hours compared to the previous system.  Labor savings is estimated at $7800/yr.
Lubricating Oil Energy Recovery 8,000 Industrial Waste $16,500 $500 $16,500 Approximately 1,000 gallons of lubricating oils were collected, tested for suitable for use as waste oil fuel, and used for energy production at the Central Steam Facility. Cost of analysis is estimated at $500.  The fuel use savings are estimated at $.50/gallon
Cooling Tower Chemicals Source Reduction 6,375 Industrial Waste $15,000 $0 $15,000 Ozone water treatment units were installed on cooling towers at two RHIC experiments to provide biological control of cooling water. These systems eliminate the need for water treatment chemicals (typically toxic biocides), save labor, and reduce analytical costs for monitoring cooling tower blowdown. Savings are estimated at $15,000/yr.
Hydraulic Oil Source Reduction 6,000 Industrial Waste $33,000 $0 $33,000 During calendar year 2001, a project (funded by the pollution prevention council) replaced hydraulic lines on heavy equipment with steel braided lines and replaced the petroleum based hydraulic oils with bio-based vegetable oils. Hydraulic line breaks were responsible for a significant number of reportable spills and costly response and clean-up. This project reduced the frequency of spills and resulting response and clean-up costs. The vegetable based oil is biodegradable and subject to fewer reporting requirements. Avoided disposal costs are based on 6000 lbs of industrial waste and  savings from reduced response and clean-up costs are estimated at $33,000.
Blasocut Machining Coolant Recycled/Reused 51,600 Industrial Waste $103,200 $0 $115,500 Central Shops Division operates a recycling system that reclaims Blasocut machining coolant and supplies it labwide. 6450 gallons (51,600 lbs.) of Blasocut lubricant were recycled in 2004. Recycling involves aeration, centrifuge, and filtration. Avoids cost of disposal as industrial waste plus an avoided cost of procurement of 6 drums of concentrate ($800/drum) and 130 drums for waste ($50/drum). Cost of recycle is estimated to be the same as cost of procurement and preparation of proper dilution for use.
Used Motor Oil Energy Recovery 30,880 Industrial Waste $65,660 $0 $65,660 Used motor oil from the motor pool and the on-site gas station is picked for free up by Strebel's Laundry Service and used to fire their waste oil dryers.  During calendar year 2004 4655 gallons of oil were picked avoiding cost for disposal and 78 drums for shipping ($50/drum)
Office Paper Recycled 370,000 Sanitary Waste $16,650 $0 $16,650 Estimate $90/ton for disposal as trash.
Cardboard Recycled 358,000 Sanitary Waste $16,110 $0 $16,110 Estimate $90/ton for disposal as trash.
Scrap Metal Recycled 256,000 Sanitary Waste $11,520 $0 $11,520 Estimate $90/ton for disposal as trash.
Bottles/Cans Recycled 44,000 Sanitary Waste $1,980 $0 $1,980 Estimate $90/ton for disposal as trash.
Construction Debris Recycled 734,000 Sanitary Waste $16,515 $0 $16,515 Estimate $45/ton for disposal as trash.
  TOTALS 2,250,783   $1,666,432 $99,700 $1,717,431  
* Cost savings of Projects funded by the BNL Pollution Prevention Council will be carried on the tracking system for three years              
putressible waste / ton 90.00
hazardous waste / pound 2.00
industrial waste / pound 2.00
Labpack / pound 16.60
radioactive liquid / pound 2.30 20 dollars per gallon per Ed Richards on 2/28/05
sewage sludge / drum n/a
non-compactible LLW / ft3 149.90
compactible LLW / ft3 88.75
high activity LLW / ft3 n/a
mixed waste / ft3 210.00